JPH05159956A - Manufacture of rectangular coil - Google Patents

Abstract

PURPOSE:To manufacture a rectangular coil by a winding frame which can be manufacturing by a smaller number of molds or only by machining. CONSTITUTION:Divided cylinders 8 formed by dividing a cylinder with a collar into four segments are disposed along positions to become inner surfaces of four corners of a rectangular winding. Further, a flat plate 9 is disposed along a position to become an inner surface of a linear part of the winding. The plate 9 and the cylinder 8 are connected by adhesive to form a bobbin 10 of a rounded square shape. A conductor winding 11 is wound in a rectangular shape along the bobbin 10 to form the rectangular coil.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a rectangular winding of a transformer or the like using a winding frame.

[0002]

2. Description of the Related Art When winding a round conductor wire or a rectangular conductor wire, a method of bending an inter-layer insulating paper to suppress it is often used as a method for preventing the end portions of the winding conductors from shifting. However, in order to speed up the winding work, the method of using the reel is advantageous. FIG. 5: is a perspective view which shows the structural example of the conventional winding frame used for manufacture of the rectangular winding of a transformer. The insulative reel 1 is composed of a square tube portion 2 and a collar portion 3. The reel is manufactured by integral casting using a die or by bonding the square tube portion 2 and the collar portion 3 together. FIG. 6 is a sectional view of a rectangular winding manufactured using the winding frame 1 of FIG. 5, in which the winding conductor 3 is wound along the winding frame 1. The rectangular winding of FIG. 6 is used in this state by inserting an iron core into the rectangular hollow portion 4, or is further housed in a mold and molded into a resin-molded winding.

[0003]

However, the conventional method as described above has a troublesome problem that many kinds of winding frames have to be prepared according to the shape of the rectangular winding. In the case of a rectangular winding, there are many combinations of long sides and short sides depending on the capacity of the transformer. Each time, I had to prepare a die for making reels. Further, a metal mold was required for manufacturing the square tube portion. Therefore, in the past, it was very expensive to manufacture the reel.

An object of the present invention is to make it possible to manufacture a rectangular winding by a winding frame which can be manufactured by an extremely small number of molds or a winding frame which can be manufactured only by machining.

[0005]

In order to achieve the above object, according to the method of the present invention, a cylinder having a flange facing outward in the radial direction is formed by circumferentially dividing the cylinder into four parts. By arranging the divided cylinders along the positions that are the inner surfaces of the four corners of the rectangular winding, and by arranging the flat plates along the positions that are the inner surfaces of the rectangular winding straight portions, and joining the flat plates and the divided cylinders to each other. An angular winding frame is formed, and the winding is wound in a rectangular shape along the winding frame.

Further, according to the method of the present invention, a divided cylinder formed by dividing a cylinder with a flange facing outward in the radial direction into four equal parts in the circumferential direction is formed in advance at four corners of the rectangular winding. A winding frame is formed by arranging along the outer surface, and the outer winding is wound in a rectangular shape along the winding frame.

[0007]

According to the method of the present invention, the divided cylinder formed by dividing the flanged cylinder into four is arranged along the positions which are the inner surfaces of the four corners of the rectangular winding. Further, a flat plate is arranged along the position that is the inner surface of the straight portion of the rectangular winding. By joining the flat plate and the divided cylinder to each other, a winding frame having a circumferential shape is formed. The winding is wound in a rectangular shape along the winding frame.
According to this method, even if the transformers have different capacities, if the bending radii of the four corners of the rectangular winding are made common, the number of divided cylinders can be extremely reduced. Therefore, the number of molds for manufacturing the reel is extremely reduced. Since the length of the long side and the short side of the rectangular winding is only the cutting out of the flat plate, the flat plate can be manufactured only by machining. Further, the shape of the divided cylinder 4 before being divided is also axially symmetric as shown in FIG. 1, so that the divided cylinder 4 can be manufactured not by die casting but by machining.

Further, according to the method of the present invention, divided cylinders formed by dividing a cylinder with a collar into four are arranged along the outer surfaces of the four corners of the inner rectangular winding. An outer winding is wound in a rectangular shape along the outside of the divided cylinder as a winding frame. According to this method, as in the case described above, the reel can be manufactured by using an extremely small number of dies, and can also be manufactured only by machining.

[0009]

EXAMPLES The present invention will be described below based on examples.
FIG. 1 is a perspective view showing the structure of a flanged cylinder used in the method of the present invention. Cylinder 5 with insulating brim is circular pipe 6
It is composed of a tongue portion 7. FIG. 2 is a plan view of a divided cylinder 8 obtained by dividing the flanged cylinder of FIG. 1 into four. FIG. 3 is a plan view showing the structure of a rectangular winding manufactured by the method of the embodiment of the present invention. The divided cylinder 8 and the flat plate 9 of FIG. 2 are adhered to each other to form the winding frame 10. The flat plate 9 is formed in a rectangular shape extending in the direction perpendicular to the figure. Along the outside of the winding frame 10, the winding conductor 1
A rectangular winding is made by winding 1.

In FIG. 3, if the bending radii of the rectangular windings are common even if the transformers have different capacities, the radius R of the divided cylinder 8 can be set to a constant value. Therefore, the flanged cylinder 5 of FIG. 1 for manufacturing the divided cylinder 8 can manufacture many kinds of rectangular windings with extremely few kinds. Therefore, even if the flanged cylinder 5 of FIG. 1 is manufactured by a mold, the number of kinds of molds required is very small.
Furthermore, since the flanged cylinder 5 has an axisymmetric shape and the flat plate 9 has a rectangular shape, both can be manufactured only by machining. Therefore, the winding frame 10 composed of the flanged cylinder 5 and the flat plate 9 can be entirely formed by machining, so that it is not always necessary to use a mold.

FIG. 4 is a plan view showing the structure of a rectangular winding manufactured by the method according to another embodiment of the present invention. The divided cylinders 8 of FIG. 2 are arranged along the outer surfaces of the four corners of the rectangular inner winding 12. Using the divided cylinder 8 as a winding frame, a winding conductor is wound around the winding frame to form a rectangular outer winding 13. In this case, the flat plate 9 is not required unlike the embodiment of FIG.
Since this is a winding method when the inner winding 12 is present in advance, the inner winding 12 sets the divided cylinder 8 at a fixed position. Therefore, also in this embodiment, only the divided cylinder 8 is required as the reel, the number of molds required is greatly reduced, and the reel can be formed only by machining.

[0012]

As described above, the method of the present invention arranges the divided cylinders, which are formed by dividing the flanged cylinder into four, along the inner surfaces of the four corners of the rectangular winding. Further, a flat plate is arranged along the position that is the inner surface of the straight portion of the rectangular winding. By joining the flat plate and the divided cylinder to each other, a winding frame having a circumferential shape is formed. The winding is wound in a rectangular shape along the winding frame. According to this method, the number of molds for the reel is extremely small, and the reel can be entirely machined. Therefore, the manufacturing cost of the rectangular winding can be significantly reduced.

Further, according to the method of the present invention, the divided cylinders formed by dividing the cylinder with a collar into four are arranged along the outer surfaces of the four corners of the inner rectangular winding. An outer winding is wound in a rectangular shape along the outside of the divided cylinder as a winding frame. With this method as well, as in the case described above, it is possible to manufacture the reel using only an extremely small number of dies, and it is also possible to perform machining only. Therefore, the manufacturing cost can be significantly reduced even when the outer rectangular winding is manufactured outside the inner rectangular winding via the winding frame.

[Brief description of drawings]

FIG. 1 is a perspective view showing a configuration of a flanged cylinder used in a method according to an embodiment of the present invention.

FIG. 2 is a plan view of a divided cylinder obtained by dividing the flanged cylinder of FIG. 1 into four parts.

FIG. 3 is a plan view showing the configuration of a rectangular winding manufactured by the method according to the embodiment of the present invention.

FIG. 4 is a plan view showing a configuration of a rectangular winding manufactured by a method according to another embodiment of the present invention.

FIG. 5 is a perspective view showing a configuration example of a conventional winding frame used for manufacturing a rectangular winding of a transformer.

6 is a cross-sectional view of a rectangular winding manufactured using the winding frame of FIG.

[Explanation of symbols]

 5 Cylinder with collar 6 Circular tube part 7 Collar part 8 Divided cylinder 9 Flat plate 10 Winding frame 11 Winding conductor 12 Inner winding 13 Outer winding

Claims (2)

[Claims] 1. A divided cylinder, which is formed by dividing a cylinder having a flange outwardly in the radial direction into four parts in the circumferential direction, is arranged along the positions which are the inner surfaces of the four corners of the rectangular winding, and is rectangular. A flat plate is arranged along the position to be the inner surface of the straight line portion of the winding, and the flat plate and the divided cylinder are joined to each other to form a winding frame having a circumferential shape. A method for manufacturing a rectangular winding, which comprises winding in a shape. 2. A divided cylinder formed by dividing a cylinder having a flange outwardly in the radial direction into four parts in the circumferential direction is arranged along the outer surfaces of the four corners of the rectangular winding which are manufactured in advance. A method for manufacturing a rectangular winding, comprising forming a winding frame and winding the outer winding in a rectangular shape along the winding frame.